GAS DETECTION
Once the optimal conditions are reached, adaptive gas reduction is activated automatically. The intelligent system reacts dynamically to changes, such as door movements or deterioration of the furnace atmosphere, and adjusts the gas volume in real time.
This ensures that an ideal protective gas atmosphere is always present in the furnace. As a result, despite the reduced gas flow, the furnace atmosphere is of even better quality than with conventional gas flow control.
Figure 2: Schematic representation of the GreenFlow system with a controlled gas atmosphere and associated gas measurement technology (
INFRA.sens®
)
Another advantage of the GreenFlow system is the combination of colder carrier gas and reduced heating energy, as well as better temperature uniformity in the furnace. The longer the process takes and the larger the furnace, the greater the savings will be.
In order to optimally control the reduced gas supply, the respective gas flow is set via the flow controllers (MFC3
) and
dynamically adjusted to the current operating conditions. This requires highly accurate gas analysis at the furnace.
The NDIR gas measuring device based on
INFRA.sens® technology selectively detects the different concentrations of carbon monoxide CO, carbon dioxide CO2
, and methane CH4 . The gas supply is then regulated on the basis of this gas analysis. Figure 5: High-resolution IR spectrum of the gases CH4 At the heart of the IGA 5.2 is an
INFRA.sens® , CO2 , and CO to be analysed gas measurement
module that can simultaneously detect a total of five gases. All measured values are transmitted digitally in real time to a Siemens PLC, which makes these values available via TCP/IP. This enables particularly dynamic control behaviour. This feature is crucial for efficiency and process stability in the GreenFlow process.
All components of the IGA 5.2 gas analyser are integrated into a robust sheet metal housing that meets protection class IP65 and can therefore be used even under harsh operating conditions (Figure 4).
An IGA 5.2 gas analyser can be used to control two hardening furnaces simultaneously, which significantly reduces investment costs and increases plant efficiency. In addition, an OPC UA connection is available, allowing the IGA 5.2 to be optimally integrated into modern Industry 4.0 infrastructures.
A novelty in industrial gas analysis technology is the complete integration of all three common C-level calculation methods:
• C-level from the EMF4 signal of the O2 probe (oxygen probe)
• C level from the CO₂ concentration • C level from the dew point measurement.
The analyser completely covers all relevant measured variables for heat treatment. The IGA 5.2 thus offers a comprehensive basis for precise gas analysis and all common calculation methods for atmosphere adjustment in the hardening process.
Figure 3: Illustration of furnace system with corresponding component description
The Ipsen IGA 5.2 gas analyser was developed specifically for the innovative GreenFlow gas injection process and sets new standards in precision, flexibility, and ease of maintenance.
The gas analyser was designed not only to measure quickly and reliably, but also to offer significantly more functionality than other products available on the market.
• CO: 0-40 vol.% • CO₂: 0-1 vol.% • CH₄: 0-10 vol.% • O₂: 0-100 vol.% • Dew point: -30 °C to +30 °C. The
INFRA.sens® parameters CO, CH4
consists of the following steps:
1. The customer requests a replacement service when the calibration certificate has expired 2. Ipsen delivers a refurbished and calibrated analyser
3. The customer takes care of commissioning themselves with the following steps:
• Simply insert the Siemens memory card from the existing device into the new analyser • Switch it on • Done → plug and play
This concept offers enormous advantages for the user:
• No downtime: Other manufacturers sometimes require several weeks for calibration because the devices have to be sent in. During this time, the process would be at a standstill, and the GreenFlow system would not be operational
• Annual warranty: Each replacement analyser comes with a one- year warranty, valid until the next service
• No specialist personnel required: All refurbishment and calibration procedures are carried out entirely at Ipsen under controlled laboratory conditions, including a full functional test and calibration certificate
• Predictable, simple annual routine.
This service concept is as innovative as it is efficient and clearly sets the IGA 5.2 apart from existing products on the market.
NDIR gas measurement technology Gas concentrations are measured using the proven
INFRA.sens modules. All required gas concentrations (CO, CO2
, and CH4 determined using the NDIR5
gas measurement module supplies the key , CO₂ O2
simultaneous use of all three calculation methods.
The three C-level measurements can be compared, visualised, and optionally transferred to higher-level systems on the integrated touch panel. This enables unprecedented transparency, safety, and redundancy in process control real technological advantages.
Service and calibration concept
Another unique feature of the IGA 5.2 is the innovative calibration and replacement service, which was specially developed to completely avoid downtime. The device replacement process
Range Methane CH4 Carbon dioxide CO2 Figure 4: Image of the Ipsen IGA 5.2 gas analyser
Oxygen O2 Humidity H2
0-10 vol.% 0-10 000ppm
Carbon monoxide CO 0-40 vol.% 0-100 vol.% 0-100 % RH
O
Prinzipal NDIR NDIR NDIR EC
and residual moisture, enabling the method [5].
This method is based on the selective absorption of infrared radiation by different gas molecules. Figure 5 shows the absorption spectra of the three gases.
Spectral overlaps that could lead to cross-sensitivities are found between CO and CO2
in the range around 4.5µm. Methane measurement is not affected by this. CO2 measurement therefore
takes place at 4.25µm, CO measurement at 4.75µm, and CH4 measurement at 3.3µm.
Spectral overlaps are ruled out by the use of narrow-band interference filters, ensuring that this type of gas measurement guarantees high selectivity [4]. The
INFRA.sens®
uses a multi- channel detector that can simultaneously detect the three gases
Table 1: Gas components that can be detected simultaneously with the
INFRA.sens® gas measurement module Gas
capacitive
Accuracy ±1% F.S. ±1% F.S. ±1% F.S. 2% F.S. ±2% RH
) are
Detection Limit <10ppm <1ppm
<10ppm
<0.005 vol.% 0.02% RH
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